Laser ablation has the potential to remove paint and other coatings from ship’s surfaces using a process that is faster, safer, and less expensive than conventional methods.

The Naval Undersea Warfare Center (NUWC) Division, Keyport and Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF) partnered to successfully demonstrate the use of laser ablation aboard the aircraft USS Carl Vinson (CVN 70) in October.

Matt Binsfield, a technical project manager in NUWC Keyport’s Rapid Prototyping and Fabrication Technology Division, said laser ablation is commonly used to remove paint and coatings from aircraft parts made of aluminum, but its use aboard steel ships is a new application of the technology.  Binsfield said NUWC Keyport conducted some of the original pioneering work in the field by developing the technology to refurbish large helicopter rotor blades, and is helping lead the effort to bring laser ablation to the shipyard.

 “We’ve done a very detailed design of the experiment which has evaluated all industry experience and reports to date,” said Binsfield.  We’re collaborating with the Air Force and Boeing to make sure we’re not doing redundant work. We’re trying to model this and set a standard for how we do new technology transition so we can be more efficient across the board.  The design of the experiment is all about making sure we capture the right information, and then share that effort so that we have a full understanding of the technical aspects of the capability, the necessary training and permitting requirements, rigorous process instructions, compliant safety instructions and cybersecurity controls.  This will be everything we need to successfully transition and sustain the capability to fleet maintainers.”

Binsfield said the ability to not only create, but sustain the technology in the fleet, will be a key to expanding the Navy’s advantage through efficient use of the new technology to get ships out of the shipyard and back to sea in a faster and safer manner.

Scott Castro, general foreman for Shop 71, Painters Blasters and Tilesetters at PSNS & IMF, said safety and the environment are also reasons why laser ablation is being explored for use aboard ships and in the shipyards.  Castro said conventional methods require extensive extra work in both preparation and clean up to ensure the protection of workers and the environment.  Laser ablation can eliminate many of those steps.

“Laser ablation technology leaves a completely clean surface, and there is no additional need to use solvents or chemicals to remove any oils, grease, or other surface contaminants,” said Castro. “Use of laser ablation technology can reduce exposure to harsh solvents or chemicals and improve worker ergonomics.”

Nicholas Bankus, a lead engineer in NUWC Keyport’s Rapid Prototyping and Fabrication Technology Division, said the operational demonstration conducted on Carl Vinson resulted in positive feedback about the equipment and its ease of use.

 “Probably the best feedback we received from the technicians was that the equipment was very easy to use and that they preferred it to conventional removal tools,” said Bankus.  Enabling workers and sailors to complete a job faster while increasing safety was critical to proving the value of laser ablation.

Dr. Kraig Frederickson, a chemical engineer in NUWC Keyport’s Rapid Prototyping and Fabrication Technology Division, has been characterizing the chemical by-products of the process to support the application for an air permit from the Puget Sound Clean Air Agency.

“Environmental analysis is one of about a half dozen different tasks to be completed in this effort and is a new capability we have established at NUWC Keyport in support of this project,” said Frederickson.  “While the laser ablation process produces smaller amounts of hazardous waste, the complex chemical and physical interactions involved drive different chemical mechanisms, which are absent in traditional methods of paint removal.  This leads to formation of a broad range of new environmental concerns that need to be identified and quantified.”

Binsfield said laser ablation is not a one-size-fits-all solution.  The immediate focus is eventual elimination of needle guns for the removal of coatings in relatively confined areas, and the successful operational demonstration aboard Carl Vinson will lead to more in-depth demonstrations on a retired Navy vessel currently in storage. 

“We’re looking at the ex-USS McKee, which is a submarine tender stored in Norfolk,” Binsfield said.  “This will allow us to better quantify the man-hours associated with each aspect of the work.”

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